Index-matching gel for nanostructure optical fibers and mechanical splice assemble and connector using same

ABSTRACT

A polymer based index-matching gel for use with nanostructure optical fibers is disclosed. The index-matching gel has a viscosity η at 25° C. of 3 Pa-s≦η≦100 Pa-s, which prevents the index-matching gel from wicking into the voids and down the nanostructure optical fiber to a depth where the fiber performance and/or device performance is compromised. The gel is suitable for use when mechanically splicing optical fibers when at least one of the optical fibers is a nanostructure optical fiber. The gel is also suitable for use in fiber optic connectors wherein at least one of the optical fibers constituting the connection is a nanostructure optical fiber.

CROSS REFERENCE TO RELATED APPLICATION

The present application is a Divisional of U.S. Ser. No. 11/985,509,filed on Nov. 15, 2007, the disclosure of which is incorporated hereinby reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to index-matching materials usedfor splicing optical fibers, and in particular relates to index-matchinggels suitable for use with nanostructure optical fibers, and the use ofsuch gels in mechanical splice assemblies and fiber optic connectors.

2. Technical Background

Optical fibers are widely used in a variety of applications, includingthe telecommunications industry in which optical fibers are employed ina number of telephony and data transmission applications. Due, at leastin part, to the extremely wide bandwidth and the low noise operationprovided by optical fibers, the use of optical fibers and the variety ofapplications in which optical fibers are used are continuing toincrease. For example, optical fibers no longer serve as merely a mediumfor long distance signal transmission, but are being increasingly routeddirectly to the home or, in some instances, directly to a desk or otherwork location.

The ever increasing and varied use of optical fibers has spurred the useof fiber optic connectors. Fiber optic connectors are used to terminatethe ends of optical fibers, and enable quicker connection anddisconnection than fusion splicing. A typical connector holds the end ofeach optical fiber in a ferrule. The ferrule serves to align therespective cores of the two fibers so that light can pass between theends of the fibers.

Connectors have traditionally been one of the main concerns in usingfiber optic systems because they introduce loss and because differentconnector types were typically not compatible. While the use ofconnectors was once problematic, manufacturers have taken steps tostandardize and simplify them. This increasing user-friendliness hascontributed to the increase in the use of fiber optic systems.

To efficiently transmit optical signals between two optical fibers, aconnector must not significantly attenuate or alter the transmittedsignals. However, while connectors provide an easy way to connect twooptical fibers (or sets of optical fibers), they also introduceattenuation, which is typically in the range from about 0.05 dB to 0.5dB. To mitigate attenuation effects in the connector, an index-matchingmaterial (typically, a fluid) is often used. The index-matching materialis held within the connector so that it presents itself at the interfacebetween the two fiber ends. The index-matching material serves to reduceattenuation due to reflections from the index mismatch at thefiber-fiber interface.

SUMMARY OF THE INVENTION

An aspect of the invention is a polymer based index-matching gel for usewith nanostructure optical fibers. The index-matching gel has at leastone polymer component that preferably has a viscosity η at 25° C. of 3Pa-s≦η≦100 Pa-s, which prevents the index-matching gel from wicking intothe voids and down the nanostructure optical fiber to a depth where thefiber performance and/or device performance is compromised. The gel issuitable for use when mechanically splicing optical fibers when at leastone of the optical fibers is a nanostructure optical fiber. The gel isalso suitable for use in fiber optic connectors wherein at least one ofthe optical fibers constituting the connection is a nanostructureoptical fiber.

Additional features and advantages of the invention will be set forth inthe detailed description which follows, and in part will be readilyapparent to those skilled in the art from that description or recognizedby practicing the invention as described herein, including the detaileddescription which follows, the claims, as well as the appended drawings.

It is to be understood that both the foregoing general description andthe following detailed description present embodiments of the invention,and are intended to provide an overview or framework for understandingthe nature and character of the invention as it is claimed. Theaccompanying drawings are included to provide a further understanding ofthe invention, and are incorporated into and constitute a part of thisspecification. The drawings illustrate various embodiments of theinvention, and together with the description, serve to explain theprinciples and operations of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic side view of an end section of a nanostructureoptical fiber cable;

FIG. 2 is a cross-sectional diagram of the nanostructure optical fibercable of FIG. 1 as viewed along the direction 2-2, and includes an insetshowing a close-up view of the void structure for an example embodimentof a nanostructure region having non-periodically arranged voids;

FIG. 3A is a schematic cross-sectional diagram of an end section of anexample nanostructure optical fiber as viewed along the length of thefiber, wherein the fiber has periodic voids, illustrating how theindex-matching gel of the present invention does not substantially fillthe nanostructure voids at the end of the nanostructure optical fiber;

FIG. 3B is a schematic diagram similar to FIG. 3A, illustrating anexample embodiment wherein the index-matching gel of the presentinvention migrates into the nanostructure voids to a maximum depthD_(M);

FIG. 4A illustrates an example index-matching gel chemical formulationfor an example embodiment of a siloxane polymer according to the presentinvention, wherein the siloxane polymer is a trimethylterminated-trimethylsiloxyphenylsiloxane polymer;

FIG. 4B illustrates an example index-matching gel chemical formulationfor an example embodiment of a siloxane polymer gel according to thepresent invention, wherein the siloxane polymer is a trimethylterminated-phenylmethylsiloxane-dimethylsiloxane copolymer;

FIG. 4C illustrates an example index-matching gel chemical formulationfor an example embodiment of a siloxane polymer gel according to thepresent invention, wherein the siloxane polymer is a trimethylterminated-diphenylsiloxane-dimethylsiloxane copolymer;

FIG. 5 is a log-log plot of viscosity (Pa-s) vs. shear rate for a priorart low-viscosity index-matching gel (the “comparative example”) and anexample embodiment of the index-matching gel of the present invention(the “inventive example”);

FIG. 6 is a schematic cross-sectional diagram of an example embodimentof a mechanical splice assembly according to the present invention,showing the index-matching gel held in the assembly, the nanostructureoptical fiber cable prior to being incorporated into the assembly;

FIG. 7 is a schematic cross-sectional diagram of the ferrule of FIG. 6;

FIG. 8 is the same mechanical splice assembly as shown in FIG. 6, butnow with the nanostructure optical fiber cable incorporated into theassembly; and

FIG. 9 is a schematic cross-sectional diagram of a simplified fiberoptic connector according to the present invention that includes themechanical splice assembly and index-matching gel of the presentinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference is now made in detail to the present preferred embodiments ofthe invention, examples of which are illustrated in the accompanyingdrawings. Whenever possible, the same reference numbers and symbols areused throughout the drawings to refer to the same or like parts.

There are a number of “nanostructure” (or “holey”) optical fibers on themarket today that have one or more regions with periodically oraperiodically arranged small holes or voids, which make the fiberextremely bend insensitive. Examples of such optical fibers aredescribed in, for example, U.S. Pat. No. 6,243,522, pending U.S. patentapplication Ser. No. 11/583,098 filed Oct. 18, 2006, and provisionalU.S. patent application Ser. Nos. 60/817,863 filed Jun. 30, 2006;60/817,721 filed Jun. 30, 2006; 60/841,458 filed Aug. 31, 2006;60/841,490 filed Aug. 31, 2006; and 60/879,164, filed Jan. 8, 2007(hereinafter, “the Corning nanostructure fiber patents and patentapplications”), all of which are assigned to Corning Incorporated andall of which are incorporated by reference herein.

One type of nanostructure optical fiber developed by Corning, Inc. hasan annular ring of non-periodic airlines (of diameter ˜1×10⁻⁷ m) thatextend longitudinally (axially) along the length of the fiber. Theregion with the ring of airlines has a reduced apparent or average indexof refraction, because air has an index of refraction of approximately 1compared to the fused silica matrix refractive index of approximately1.46. The ring of airlines is positioned to create a refractive indexprofile that enables superior bend performance (optically) andsignificantly smaller minimum bend radius specifications.

The use of nanostructure optical fibers in combination withindex-matching material, however, can be problematic. Certainindex-matching materials are commonly used for non-nanostructure opticalfibers. However, such materials could possibly migrate (or “wick”) intothe airlines (voids) from the fiber end-face over time. This movementmay also occur with variations in temperature. Filling the airlines witha material index-matched to silica raises their index of refraction fromapproximately 1 to approximately 1.46, resulting in a change in thefiber index profile, which leads to increased optical loss when thefiber is bent. This reduces or eliminates an important property ofenhanced bend performance of the nanostructure fiber. Likewise, in ananostructure fiber in the form of a photonic crystal fiber or “holeyfiber,” the fiber attenuation (straight fiber) is increasedsubstantially when the holes are filled with an index-matching material.

Example Nanostructure Optical Fiber Cable

The index-matching gel of the present invention is suitable for use inconnection with nanostructure optical fibers, and in particular forforming mechanical splices with one or more of such fibers in mechanicalsplice assemblies used in fiber optic connectors.

FIG. 1 is a schematic side view of a section of an example embodiment ofnanostructure optical fiber cable 110 that includes a nanostructureoptical fiber 112 with a protective cover 114. Nanostructure opticalfiber 112 has an end 120 and a central axis A_(F). FIG. 2 is a schematiccross-section of cable 110 as viewed along the direction 2-2 in FIG. 1.Nanostructure optical fiber cable 110 can include, for example, any oneof the various types of nanostructure optical fibers 112, such as any ofthe so-called “holey” fibers, or those described in the above-mentionedCorning nanostructure fiber patents and patent applications. In anexample embodiment, nanostructure optical fiber 112 includes a coreregion (“core”) 220, a nanostructured region 230 surrounding the core,and a cladding region 240 (“cladding”) surround the nanostructuredregion. Other ring-type configurations for nanostructure optical fiber112 are also known.

In an example embodiment, nanostructured region 230 comprises a glassmatrix (“glass”) 231 having formed therein non-periodically disposedholes (also called “voids” or “airlines”) 232, such as the example voidsshown in detail in the magnified inset of FIG. 2. In another exampleembodiment, voids 232 may be periodically disposed, such as in aphotonic crystal optical fiber, wherein the voids typically havediameters in between about 1×10⁻⁶ m and 1×10⁻⁵ m. Voids 232 may also benon-periodic airlines. In an example embodiment, glass 231 isfluorine-doped while in another example embodiment the glass is undopedpure silica. By “non-periodically disposed” or “non-periodicdistribution,” it is meant that when one takes a cross-section of theoptical fiber (such as shown in FIG. 2), the voids 232 are randomly ornon-periodically distributed across a portion of the fiber. Crosssections similar to FIG. 2 taken at different points along the length ofnanostructure optical fiber 110 will reveal different cross-sectionalhole patterns, i.e., various cross-sections will have different holepatterns, wherein the distributions of holes and sizes of holes do notmatch. That is, the holes are non-periodic, i.e., they are notperiodically disposed within the fiber structure. These holes arestretched (elongated) along the length (i.e. in a direction generallyparallel to the longitudinal axis) of the optical fiber (and thus have alonger dimension along the length of the fiber), but do not extend theentire length of the entire fiber for typical lengths of transmissionfiber. While not wishing to be bound by theory, it is believed that theholes extend less than a few meters, and in many cases less than 1 meteralong the length of the fiber.

If non-periodically disposed holes/voids 232 are employed innanostructured region 230, it is desirable in one example embodimentthat they be formed such that greater than 95% of and preferably all ofthe holes exhibit a mean hole size in the cladding for the optical fiberwhich is less than 1550 nm, more preferably less than 775 nm, mostpreferably less than about 390 nm Likewise, it is preferable that themaximum diameter of the holes in the fiber be less than 7000 nm, morepreferably less than 2000 nm, and even more preferably less than 1550nm, and most preferably less than 775 nm In some embodiments, the fibersdisclosed herein have fewer than 5000 holes, in some embodiments alsofewer than 1000 holes, and in other embodiments the total number ofholes is fewer than 500 holes in a given optical fiber perpendicularcross-section. Of course, the most preferred fibers will exhibitcombinations of these characteristics. Thus, for example, oneparticularly preferred embodiment of optical fiber would exhibit fewerthan 200 holes in the optical fiber, the holes having a maximum diameterless than 1550 nm and a mean diameter less than 775 nm, although usefuland bend resistant optical fibers can be achieved using larger andgreater numbers of holes. The hole number, mean diameter, max diameter,and total void area percent of holes can all be calculated with the helpof a scanning electron microscope at a magnification of about 800× toabout 4000× and image analysis software, such as ImagePro, which isavailable from Media Cybernetics, Inc. of Silver Spring, Md., USA.

In an example embodiment, holes/voids 232 can contain one or more gases,such as argon, nitrogen, or oxygen, or the holes can contain a vacuumwith substantially no gas; regardless of the presence or absence of anygas, the refractive index of the hole-containing region is lowered dueto the presence of the holes. The holes can be non-periodically ornon-periodically disposed, while in other embodiments the holes aredisposed periodically. In some embodiments, the plurality of holescomprises a plurality of non-periodically disposed holes and a pluralityof periodically disposed holes. Alternatively, or in addition, asmentioned above the depressed index can also be provided by downdopingthe glass in the hole-containing region (such as with fluorine) orupdoping one or both of the surrounding regions.

Nanostructured region 230 can be made by methods that utilize preformconsolidation conditions, which are effective to trap a significantamount of gases in the consolidated glass blank, thereby causing theformation of voids in the consolidated glass optical fiber preform.Rather than taking steps to remove these voids, the resultant preform isused to form an optical fiber with voids, or holes, therein. As usedherein, the diameter of a hole is the longest line segment whoseendpoints are disposed on the silica internal surface defining the holewhen the optical fiber is viewed in perpendicular cross-sectiontransverse to the optical fiber central axis A_(F).

An example nanostructure fiber 112 was analyzed in connection with usingthe index-matching gel 100 of the present invention. SEM analysis of theend face of an example nanostructure optical fiber 112 showed anapproximately 4.5 micron radius GeO2-SiO2 void-free core (having anindex of approximately +0.34 percent delta verses silica) surrounded bya 11 micron outer radius void-free near clad region surrounded by 14.3micron outer radius non-periodic void-containing cladding region (ringthickness of approximately 3.3 microns), which is surrounded by avoid-free pure silica outer cladding having an outer diameter of about125 microns (all radial dimensions measured from the center of theoptical fiber).

The nanostructure region comprised approximately 2.5 percent regionalarea percent holes (100 percent N2 by volume) in that area with anaverage diameter of 0.28 microns and the smallest diameter holes at 0.17microns and a maximum diameter of 0.48 microns, resulting in about 130total number of holes in the fiber cross-section. The total fiber voidarea percent (area of the holes divided by total area of the opticalfiber cross-section×100) was about 0.05 percent. Optical properties forthis fiber were 0.36 and 0.20 dB/Km at 1310 and 1550 nm, respectively,and a 22 meter fiber cable cutoff of about 1250 nm, thereby making thefiber single mode at wavelengths above 1250 nm

Index-Matching Gel

An example of a common index-matching material used today withconventional (i.e., non-nanostructured) optical fibers is alow-viscosity index polymer with a molecular weight typically less than30,000 Daltons to which is added a small amount of gelling agent, suchas fumed silica or metal soap to make the gel phixotropic. Suchmaterials are popular because they are inexpensive and do not requiresignificant technical expertise to manufacture.

Although index-matching gels having certain refractive indices can beformed using polymers, and methods for their production are known in theprior art, the importance of higher molecular weight (Mw) gels inconnection with nanostructure optical fibers has heretofore not beenrecognized Unfortunately, conventional index-matching materials are notsuitable for fiber splicing when one of the optical fibers is ananostructure optical fiber. This is because the index-matching materialcould fills voids 232 at end 120 of the nanostructure optical fiber andthus change the effective refractive index of nanostructured region 232at the fiber end. This, in turn, leads to undesirable loss at thefiber-fiber interface, as well as a deterioration in bend performance.

Accordingly, the present invention includes mechanical splice assembly10 (described below in connection with FIG. 6 through FIG. 8) and aconnector 300 (described below in connection with FIG. 9) that includean index-matching gel 100 according to the present invention, whereinthe gel is constituted in one example embodiment so that it does notsubstantially fill voids 232 at fiber end 120, as illustrated in FIG.3A.

As illustrated in FIG. 3B, in an example embodiment of the invention,index-matching gel 100 is capable of migrating into voids 232 to a depthD_(M) as measured from fiber end 120. However, unlike conventionalindex-matching gels, the gel of the present invention that migrates intovoids 232 only does so to a limited maximum depth D_(M) that does notsubstantially impair the functionality of fiber relative to its intendeduse. For example, nanostructure optical fiber 112 may be used in aconnector (i.e., is connectorized), and depth D_(M) may be such that themaximum extent of the gel migration does not extend to beyond theconnector housing, or beyond the connector boot (which in an exampleembodiment of a present-day fiber optic connector would be about 40 mm).Since the portion of nanostructure optical fiber 112 held within theconnector housing or the connector boot is not likely to be subject tosignificant bending forces, the filling of voids 232 by gel migration toa limited depth D_(M) in such a case does not present a significant riskof performance reduction.

An example embodiment gel 100 of the present invention is based on asiloxane polymer having the following general chemical formula:

wherein R₁, R₂, R₃ and R₄ can be the same, or can be different. Thegroup may include a C₁-C₁₂ alkyl group (e.g. methyl, ethyl and thelike), a C₁-C₁₂ alkoxy group (e.g. methoxy, ethyoxy and the like), anaromatic group, a halogenated (F, Cl, Br; most preferred Cl) aromatic oralkyl group, or trimethylsiloxy.

The refractive index of a polysiloxane polymer component is adjustableby the inclusion of diphenyl siloxane or phenyl-methyl siloxane.Although other refractive-index-modifying groups such as cyclo-alkylgroups or aromatic groups can also be used, typical co-polymers foroptical index matching compositions includedimethylsiloxane-phenylmethylsiloxane co-polymers ordimethylsiloxane-diphenylsiloxane co-polymers. Mixtures of two or moresilicones polymers containing nearly the same aryl-alkyl (typicallyphenyl-methyl) ratio, at least one having a higher and one having alower viscosity, can be mixed to obtain the correct viscosity and arefractive index to match optical core. In some cases mixtures of two ormore polymers (preferably, silicones, having different viscosities, atleast one having a higher and one having a lower viscosity, anddifferent refractive indices, at least one having a higher and onehaving a lower refractive index, can be mixed to, can be mixed to obtainthe correct viscosity and a refractive index to match core 220. Theseformulations may not perfectly match the refractive index of core 220,but the matches can be made sufficiently close (at a wavelength ofoperation of the fiber) to avoid significant attenuation of the signalover the short path lengths within fiber optic connectors.

At a phenyl content of approximately 12-15 mole %, a polydimethylsiloxane/methylphenylsiloxane co-polymer has a refractive index thatsubstantially matches that of fiber core 220 while rendering the indexmatching gel transparent or substantially transparent at the wavelengthsused in optical fiber communications. Other co- or ter-polymers thatcontain the appropriate proportion of aryl and alkyl groups also producegels 100 that are transparent and index matching. Refractive index n_(i)matching of the gel to the fiber core when measured at 25° C. and atapproximately 589.3 nm wherein ≦5%, more preferably ≦2%, most preferably≦1%.

In an example embodiment, the polymer (polymer component) in gel 100 hasa molecular weight Mw such that its viscosity at 25° C., when applied tothe connector/nanostructured fiber, is in a range from 3 to 100 Pa-s,preferably 5 to 50 Pa-s, most preferably 5 to 20 Pa-s. An exampleembodiment of siloxane polymer gel 100 has a molecular weight Mw>25,000daltons. In another example embodiment, siloxane polymer gel 100 has amolecular weight in the range from 25,000 daltons<Mw<50,000 daltons. Ina further example embodiment, siloxane polymer gel 100 has a molecularweight Mw<50,000 daltons for a cured, cross-linkable version of the gel.

In an example embodiment, the molecular weight Mw of gel 100 isoptimized for a particular type of nanostructure optical fiber 112. Forexample, a nanostructure optical fiber 112 that includes photoniccrystals has relatively large voids (e.g., diameter ˜1×10⁻⁶ to ˜1×10⁻⁵m) and so may require a gel having a molecular weight Mw on the high-endof the range.

The liquid polymers may comprise a composition capable of being furtherpolymerized or crosslinked by means of heat or actinic radiation. Suchcompositions may contain monomers, oligomers, and higher molecularweight, liquid pre-polymers (including liquid silicone pre-polymers)having the required refractive index that have attached thereto vinyl,acrylate, epoxy, isocyanate, silane, hydrosilane, and otherpolymerizable functional groups well known to those skilled in thepolymer art. Typically polymerizable compositions also containinitiators, catalysts, accelerators, sensitizers, and the like tofacilitate the polymerization process.

Other embodiments of the invention include polymeric index matchingmaterials selected from the group of polymers or polymer mixtures suchas polybutenes, (meth)acrylates, acrylics, epoxies, polyesters,polyethers, polycaprolactones, polycarbonates, polybutadienes,polyurethanes, natural hydrocarbons, and other polymers well known tothose skilled in the polymer art, including blends and copolymers of theabove.

In an example embodiment, gel 100 is index-matched to provide the leastpossible amount of optical loss from reflection at fiber-fiber interface122 formed by stub-fiber end 72 and nanostructure optical fiber end 120.In another example embodiment, gel 100 may be index matched (ornon-index matched, as the case may be) and applied to end 120 ofnanostructure optical fiber 100 to “seal” the end to prevent the ingressof other materials in the ambient environment. This may be done, forexample, in connection with the treatment of cable ends or hardwarecable stubs during shipment or installation to prevent migration ofwater, oils, etc, into voids 232 at open fiber end 120.

Comparison of Index-Matching Gels

An example embodiment of index-matching gel 100 of the present inventionwas compared to a prior art index-matching gel. In both gels, theviscosity for the polymers used was measured at approximately 25° C. ina cone and plate rheometer at a shear rate γ of 12 sec⁻¹.

The prior art index-matching gel was a low viscosity polymer made up ofdimethyl-diphenyl silicone copolymer and having a viscosity ofapproximately 1.5 Pa-s, a weight average molecular weight Mw ofapproximately 24000 daltons, and a polydispersity of approximately 1.7(measured vs. polystyrene standard). Gel 100 of the present inventionwas a high viscosity polymer made up of dimethyl-diphenyl siliconecopolymer and had a viscosity of approximately 8 Pa-s, a weight averagemolecular weight of approximately 49000 daltons, and a polydispersity ofapproximately 2.1 (measured vs. polystyrene standard). Both gels hadrefractive indices of approximately 1.46 at 593 nm measured at 25° C.Gels made from these polymers comprised approximately 5 weight percentfumed silica (e.g., Cabosil™ TS-720), which makes the gels phixotropicand thus suitable for use in a splicing assembly and/or fiber opticconnector.

In one test, both index matching gels were used in respective fieldinstallable connectors. The connectors were cycled between −40 and +75°C. following Bellcore GR326 temperature cycling for 14 days, and amacrobend attenuation increase for a 10 mm diameter bend at the end ofthe connector boot, which is approx 40 mm from the fiber end-face, wasmeasured. For the high viscosity polymer-based gel of the presentinvention, the macrobend attenuation increase was <0.05 dB/turn, whilefor the low viscosity polymer-based prior art gel, the macrobendattenuation was >0.5 dB/turn.

FIG. 5 is a log-log plot of the viscosity (Pa-s) as a function of sheerrate γ (s⁻¹) for the above-described high and low viscosity gels (the“inventive example” and the “comparative example,” respectively). As canbe seen from the plot, the example index-matching gel of the presentinvention has a substantially higher viscosity as a function of thesheer rate than the prior art index-matching gel. This propertycorresponds to the reduced macrobend attenuation of the high-viscositygel of the present invention. The reduced macrobend attenuationassociated with the index-matching gel of the present invention is dueto the lack of migration of the gel into the voids as compared to theprior art low-viscosity index-matching gel.

Example Mechanical Splice Assembly

Aspects of the present invention include mechanical splice assemblies,and fiber optic connectors having such splice assemblies, that utilizethe index-matching gel of the present invention. This makes themechanical splice assemblies and connectors suitable for use with one ormore nanostructure optical fibers, such as those described in theaforementioned Corning nanostructure fiber patents and patentapplications. The example embodiment of the mechanical splice assembliesand fiber optic connectors of the present invention as describedhereinbelow are based on simplified assemblies and connectors in orderto illustrate the underlying principles of the invention. One skilled inthe art will recognize that the assemblies and connectors of the presentinvention as described herein can be implemented with a number ofspecific types of fiber optic connectors, such as those described inU.S. Pat. Nos. 4,923,274, 6,816,661 and 7,104,702, which patents areincorporated by reference herein.

FIG. 6 is a schematic cross-sectional view of an example embodiment of amechanical splice assembly 10 according to the present invention.Assembly 10 includes a ferrule 20, which is shown by itself in FIG. 7for ease of illustration and explanation. With reference to FIG. 7,ferrule 20 includes first and second ends 22 and 24, and outer surface26. Ferrule 20 includes an interior chamber 30 with front and rear openends 32 and 34 that open to respective front and rear channels 42 and44. Front channel 42 includes an open end 43 at ferrule end 22, and rearchannel 44 has an open end 45 at ferrule end 24. Optical fiber channel42 is sized to accommodate a bare optical fiber, while optical fiberchannel 44 is sized to accommodate a field optical fiber that includesits protective cover, as discussed below.

Assembly 10 further includes frontward and rearward guides 52 and 54arranged within chamber 30 at front and rear openings 32 and 34,respectively. Guides 52 and 54 are sized to pass a bare optical fiberand support the optical fiber within chamber 30. In an exampleembodiment, assembly 10 includes a retaining ring 60 on outer surface 26at or near ferrule end 22 so that the assembly can reside within aferrule holder of a fiber optic connector, as discussed below.

With reference again to FIG. 6, assembly 10 includes a section ofoptical fiber 70, referred to as a “fiber stub,” arranged in frontchannel 42 and that passes through front guide 52 such that a portion ofthe fiber stub protrudes part way into chamber 30. Fiber stub 70includes a front end 72 that is polished and flush with ferrule end 22.Fiber stub 70 also includes a rear end 74 that resides within chamber 30and that is flat or cleaved at an angle. Chamber 30 is filled with anindex-matching high-molecular-weight gel 100, which is described ingreater detail below. Fiber stub 70 may be formed from either ananostructure optical fiber or a non-nanostructure optical fiber.

With continuing reference to FIG. 6, mechanical splice assembly 10 isadapted to accommodate, via ferrule end 24, an end-portion 108 ofnanostructure optical fiber cable 110, including protective cover 114.Nanostructure optical fiber end 120 is preferably flat or cleaved whenused in assembly 10.

FIG. 8 is a schematic side view similar to FIG. 6, illustrating thenanostructure optical fiber cable 110 incorporated into mechanicalsplice assembly 10. Nanostructure optical fiber 112 is introduced intorear channel 44 at ferrule rear end 24 and is passed through rear guide54 until nanostructure optical fiber end 120 interfaces with fiber stubrear end 74 in chamber 30 at fiber-fiber interface 122. Nanostructureoptical fiber cable 110 is also held in rear channel 44, which is sizedto fit the cable with outer jacket 114. In order to ensure a proper fitof end portion 108 of nanostructure optical fiber cable 110 in assembly10, outer jacket 114 is stripped back by a length corresponding to thedistance D_(s) between fiber stub rear end 74 and rear chamber opening34 (FIG. 6).

Note that in an example embodiment of the mechanical splice assembly 10of FIG. 6, stub fiber 72 may be formed from a section a nanostructureoptical fiber, and the field optical fiber described above as ananostructure optical fiber cable 110 may be a non-nanostructure opticalfiber cable.

Example Connector

FIG. 9 is a schematic cross-sectional diagram of a simplified fiberoptic connector 300 according to the present invention that includesmechanical splice assembly 10. Connector 300 includes a connectorhousing 302 having an interior 301, front and back ends 304 and 306 anda central axis A_(c) that runs through the interior. Housing 302 housesin interior 301 a ferrule holder 310 that has a front end 311 with afront-end portion 312 sized to accommodate mechanical splice assembly10. Ferrule holder 310 also includes a back end portion 314 with a backend 313 sized to receive a support ferrule 320 that in turn is sized tohold a field fiber cable—which in the present example embodiment is ananostructured fiber cable 110.

Connector 300 also includes a crimp ring 330 arranged around ferruleholder 310 at back end 314. Crimp ring 330 is crimpled to cause the backportion of ferrule holder 310 and support ferrule 320 held therein tosqueeze nanostructure optical fiber 110 in order to providestrain-relief A flexible connector tail 350 is connected to housing backend 306 and to nanostructure optical fiber cable 10 to provide furtherstress relief Housing front end 304 includes an alignment member 370that serves to align and hold connector 300 to another connector or tothe device port to which connector 300 is to be connected.

Connector 300 is particularly well-suited for use in the field wherenanostructure optical fiber cables are used as field cables. Connector300 can be field-installed on a nanostructure field cable using the sameor similar techniques used to field-install conventional SC, LC andST®-compatible connectors, such as for example Corning UniCam®Connectors, made by Corning Cable Systems, Hickory, N.C.

It will be apparent to those skilled in the art that variousmodifications and variations can be made to the present inventionwithout departing from the spirit and scope of the invention. Thus it isintended that the present invention cover the modifications andvariations of this invention provided they come within the scope of theappended claims and their equivalents.

What is claimed is:
 1. A mechanical splice assembly, comprising: a bodyhaving opposite front and back ends, an interior chamber between thefront and back ends, and front and rear channels open to the interiorchamber and open at the respective front and back ends; a first opticalfiber having an end and disposed in the front channel so that the firstoptical fiber end resides within the interior chamber; and an indexmatching gel contained in the interior chamber, the index-matching gelcomprising at least one polymer component having a viscosity η at 25° C.such that 3 Pa-s≦η≦100 Pa-s and includes a siloxane polymer having amolecular weight Mw>25,000 daltons, wherein the index-matching gel iscurable and cross-linkable.
 2. The mechanical splice assembly of claim1, further including: a second optical fiber having an end and ananostructure region with voids, wherein the second optical fiber isdisposed within the rear channel so that the second optical fiber end isinterfaced with the first optical fiber end within the interior chamberand so that the index-matching gel provides index-matching between thefirst optical fiber end and the second optical fiber end withoutsubstantially filling the voids of the second optical fiber.
 3. Themechanical splice assembly of claim 1, wherein the first optical fiberincludes a nanostructure region with voids.
 4. The mechanical spliceassembly of claim 1, wherein the first optical fiber is a stub fiberthat extends to the body front end.
 5. The mechanical splice assembly ofclaim 1, wherein the first and second optical fibers are not the sametype of optical fiber.
 6. The mechanical splice of claim 1, wherein thebody comprises a ferrule.